POWRTWIN™ PLUS

0120 • Form No. 0537853D

AIRLESS, HIGH-PRESSURE SPRAYING UNIT

AIRLESS HOCHDRUCK-SPRITZGERÄT

GROUPE DE PROJECTION À HAUTE PRESSION

- GB - OPERATING MANUAL 2

- D - BETRIEBSANLEITUNG 28

- F - MODE D’EMPLOI 56

OPERATING MANUAL

Models:PT4900 (230V) 0290032PT4900 (Gas) 0290012PT6900 (Gas) 0290013PT8900 (Gas) 0290018PT12000 (Gas) 0290016

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Warning!Attention: Danger of injury by injection!

Airless units develop extremely high spraying pressures.

Be safety conscious!

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Never put your fingers, hands or any other parts of the body into the spray jet!Never point the spray gun at yourself, other persons or animals.Never use the spray gun without safety guard.

Do not treat a spraying injury as a harmless cut. In case of injury to the skin through coating materials or solvents, consult a doctor immediately for quick and expert treatment. Inform the doctor about the coating material or solvent used.

The operating instructions state that the following points must always be observed before starting up: 1. Faulty units must not be used. 2. Secure Titan spray gun using the safety catch on the trigger. 3. Ensure that the unit is properly earthed. 4. Check allowable operating pressure of high-pressure hose and spray

gun. 5. Check all connections for leaks.

The instructions regarding regular cleaning and maintenance of the unit must be strictly observed.Before any work is done on the unit or for every break in work the following rules must be observed: 1. Release the pressure from spray gun and hose. 2. Secure the Titan spray gun using the safety catch on the trigger. 3. Switch off unit.

Original Operating Manual

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Contents

Page 1. Safety regulations for Airless spraying ...................................... 21.1 Explanation of symbols used .............................................................. 21.2 Electrical safety ......................................................................................... 31.3 Gasoline engine safety .......................................................................... 41.4 Fueling (gas engine) ............................................................................... 4

2. General view of application ............................................................. 52.1 Application ................................................................................................ 52.2 Coating materials .................................................................................... 5

3. Description of unit................................................................................ 53.1 Airless process .......................................................................................... 53.2 Functioning of the unit ......................................................................... 53.3 System diagram - gasoline PT units .................................................. 63.4 System diagram - electric PT units .................................................... 73.5 Technical data for PT units ................................................................... 83.6 Airless Spray Tip Recommendation Chart ...................................... 9

4. Operation ................................................................................................104.1 Setup ..........................................................................................................104.2 Preparing a new sprayer .....................................................................114.3 Preparing to paint .................................................................................124.4 Painting .....................................................................................................134.5 Pressure relief procedure ...................................................................13

5. Cleanup ....................................................................................................145.1 Special cleanup instructions for use with flammable solvents ..............................................................................145.2 Cleaning the sprayer ............................................................................145.3 Cleaning a clogged tip ........................................................................14

6. Maintenance..........................................................................................156.1 Daily maintenance ................................................................................156.2 Maintaining the filter assembly........................................................156.3 Maintaining the hydraulic system ...................................................176.4 Maintaining the fluid section ............................................................176.5 Basic engine maintenance .................................................................176.6 Replacing the motor brushes (120V electric convertokit) ......186.7 Replacing the belt .................................................................................196.8 Servicing the hydraulic motor ..........................................................206.9 Servicing the fluid section ..................................................................226.10 SAE O-ring fitting installation ...........................................................24

Page 7. Troubleshooting .................................................................................257.1 Airless gun ...............................................................................................257.2 Fluid section ............................................................................................257.3 Hydraulic motors ...................................................................................267.4 Spray patterns ........................................................................................27

Accessories and spare parts ........................................................................84Spare parts list for the main assembly .................................................. 84/85Spare parts list for the cart assembly .................................................... 86/87Spare parts list for the hydraulic system .............................................. 88/89Spare parts list for the hydraulic motor ............................................... 90/91Spare parts list for the fluid section • PT4900 ..................................... 92/93Spare parts list for the fluid section • PT6900 / PT8900 / PT12000 ...................................................................... 94/95Spare parts list for gas convertokit ........................................................ 96/97Spare parts list for electric convertokit (230V) ................................... 98/99Spare parts list for the high-pressure filter ..............................................100Spare parts list for belt guard assembly ....................................................101Spare parts list for bleed hose assembly with valve .............................102Spare parts list for bleed valve .....................................................................103Spare parts list fo siphon hose assembly ..................................................104

Connection diagram (230V) .......................................................................105

Accessories for PT units ...............................................................................106Gun manifold assemblies (optional) ................................................ 108/109

Warranty .............................................................................................................112

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1. Safety regulations for Airless spraying1.1 Explanation of symbols usedThis manual contains information that must be read and understood before using the equipment. When you come to an area that has one of the following symbols, pay particular attention and make certain to heed the safeguard.

This symbol indicates a potential hazard that may cause serious injury or loss of life. Important safety information will follow.

Attention

This symbol indicates a potential hazard to you or to the equipment. Important information that tells how to prevent damage to the equipment or how to avoid causes of minor injuries will follow.

Danger of skin injection

Danger of fire from solvent and paint fumes

Danger of explosion from solvent, paint fumes and incompatible materials

Danger of injury from inhalation of harmful vapors

i Notes give important information which should be given special attention.

HAZARD: INJECTION INJURYA high pressure stream produced by this equipment can pierce the skin and underlying tissues, leading to serious injury and possible amputation.Do not treat a spraying injury as a harmless cut. In case of injury to the skin through coating materials or solvents, consult a doctor immediately for quick and expert treatment. Inform the doctor about the coating material or solvent used.

PREVENTION: • NEVER aim the gun at any part of the body. • NEVER allow any part of the body to touch the fluid stream.

DO NOT allow body to touch a leak in the fluid hose. • NEVER put your hand in front of the gun. Gloves will not

provide protection against an injection injury. • ALWAYS lock the gun trigger, shut the fluid pump off and

release all pressure before servicing, cleaning the tip guard, changing tips, or leaving unattended. Pressure will not be released by turning off the engine. The PRIME/SPRAY valve or pressure bleed valve must be turned to their appropriate positions to relieve system pressure.

• ALWAYS keep tip guard in place while spraying. The tip guard provides some protection but is mainly a warning device.

• ALWAYS remove the spray tip before flushing or cleaning the system.

• NEVER use a spray gun without a working trigger lock and trigger guard in place.

• All accessories must be rated at or above the maximum operating pressure range of the sprayer. This includes spray tips, guns, extensions, and hose.

HAZARD: HIGH PRESSURE HOSEThe paint hose can develop leaks from wear, kinking and abuse. A leak can inject material into the skin. Inspect the hose before each use.

PREVENTION: • Avoid sharp bending or kinking of the high-pressure hose. The

smallest bending radius amounts to about 20 cm. • Do not drive over the high-pressure hose. Protect against

sharp objects and edges. • Replace any damaged high-pressure hose immediately. • Never repair defective high-pressure hoses yourself! • Electrostatic charging of spray guns and the high-pressure

hose is discharged through the high-pressure hose. For this reason the electric resistance between the connections of the high-pressure hose must be equal to or lower than 1MΩ.

• For reasons of function, safety and durability use only original Titan high-pressure hoses.

• Before each use, check all hoses for cuts, leaks, abrasion or bulging of cover. Check for damage or movement of couplings. Immediately replace the hose if any of these conditions exist. Never repair a paint hose. Replace it with another earthed high-pressure hose.

• Make sure power cord, air hose and spray hoses are routed in such a manner to minimize slip, trip and fall hazard.

HAZARD: EXPLOSION OR FIREFlammable vapors, such as solvent and paint vapors, in work area can ignite or explode.

PREVENTION: • Use equipment only in well ventilated area. Keep a good

supply of fresh air moving through the area to keep the air within the spray area free from accumulation of flammable vapors. Keep pump assembly in well ventilated area. Do not spray pump assembly.

• Electric models only - Do not use materials with a flashpoint below 38º C (100º F). Flashpoint is the temperature at which a fluid can produce enough vapors to ignite.

• Gas models only - Do not fill fuel tank while engine is running or hot; shut off engine and allow to cool. Fuel is flammable and can ignite or explode if spilled on a hot surface.

• Eliminate all ignition sources, such as pilot lights, cigarettes, portable electric lamps and plastic drop cloths (potential static arc).

• Keep work area free of debris, including solvent, rags and gasoline.

• Do not plug or unplug power cords, or turn power or light switches on or off when flammable vapors are present.

• Ground equipment and conductive objects in work area. Make sure the grounding cable (not equipped) is connected from the grounding lug to a true earth ground.

• Use only grounded hoses. • Hold spray gun firmly to the side of a grounded pail when

triggering into pail. • If there is static sparking or if you feel a shock, stop operation

immediately.

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• Know the contents of the paint and solvents being sprayed. Read all Material Safety Data Sheets (MSDS) and container labels provided with the paints and solvents. Follow the paint and solvent manufacturer’s safety instructions.

• Do not use a paint or solvent containing halogenated hydrocarbons. Such as chlorine, bleach, mildewcide, methylene chloride and trichloroethane. They are not compatible with aluminum. Contact the coating supplier about compatibility of material with aluminum.

• Keep a fire extinguisher in work area.

HAZARD: HAZARDOUS VAPORSPaints, solvents, and other materials can be harmful if inhaled or come in contact with body. Vapors can cause severe nausea, fainting, or poisoning.

PREVENTION: • Wear respiratory protection when spraying. Read all

instructions supplied with the mask to be sure it will provide the necessary protection.

• All local regulations regarding protection against hazardous vapors must be observed.

• Wear protective eyewear. • Protective clothing, gloves and possibly skin protection cream

are necessary for the protection of the skin. Observe the regulations of the manufacturer concerning coating materials, solvents and cleaning agents in preparation, processing and cleaning units.

HAZARD: GENERALThis product can cause severe injury or property damage.

PREVENTION: • Follow all appropriate local, state, and national codes

governing ventilation, fire prevention, and operation. • Pulling the trigger causes a recoil force to the hand that is

holding the spray gun. The recoil force of the spray gun is particularly powerful when the tip has been removed and a high pressure has been set on the airless pump. When cleaning without a spray tip, set the pressure control knob to the lowest pressure.

• Use only manufacturer authorized parts. User assumes all risks and liabilities when using parts that do not meet the minimum specifications and safety devices of the pump manufacturer.

• ALWAYS follow the material manufacturer’s instructions for safe handling of paint and solvents.

• Clean up all material and solvent spills immediately to prevent slip hazard.

• Wear ear protection. This unit can produce noise levels above 85 dB(A).

• Never leave this equipment unattended. Keep away from children or anyone not familiar with the operation of airless equipment.

• Do not spray on windy days. • The device and all related liquids (i.e. hydraulic oil) must be

disposed of in an environmentally friendly way.

1.2 Electric SafetyElectric models must be earthed. In the event of an electrical short circuit, earthing reduces the risk of electric shock by providing an escape wire for the electric current. This product is equipped with a cord having an earthing wire with an appropriate earthing plug. Connection to the mains only through a special feed point, e.g. through an error protection insallation with INF < 30 mA.

DANGER — Work or repairs at the electrical equipment may only be carried out by a skilled electrician. No liability is assumed for incorrect installation. Switch the unit off. Before all repair work, unplug the power plug from the outlet.

Danger of short-circuits caused by water ingressing into the electrical equipment. Never spray down the unit with high-pressure or high-pressure steam cleaners.

Work or repairs at the electrical equipment:These may only be carried out by a skilled electrician. No liability is assumed for incorrect installation.

Operating TemperatureThis equipment will operate correctly in its intended ambient, at a minimum between +10°C and +40°C.Relative HumidityThe equipment will operate correctly within an environment at 50% RH, +40°C. Higher RH may be allowed at lower temperatures.Measures shall be taken by the Purchaser to avoid the harmful effects of occasional condensation.AltitudeThis equipment will operate correctly up to 2100 m above mean sea level.Transportation and StorageThis equipment will withstand, or has been protected against, transportation and storage temperatures of -25°C to +55°C and for short periods up to +70°C.It has been packaged to prevent damage from the effects of normal humidity, vibration and shock.

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1.3 Gasoline Engine Safety 1. Gas engines are designed to give safe and dependable service

if operated according to instructions. Read and understand the engine manufacturer’s Owner’s Manual before operating the engine. Failure to do so could result in personal injury or equipment damage.

2. To prevent fire hazards and to provide adequate ventilation, keep the engine at least 1 meter (3 feet) away from buildings and other equipment during operation. Do not place flammable objects close to the engine.

3. People who are not operating the device must stay away from the area of operation due to a possibility of burns from hot engine components or injury from any equipment the engine may be used to operate.

4. Know how to stop the engine quickly, and understand the operation of all controls. Never permit anyone to operate the engine without proper instructions.

5. Gasoline is extremely flammable and is explosive under certain conditions.

6. Refuel in a well-ventilated area with the engine stopped. Do not smoke or allow flames or sparks in the refueling area or where gasoline is stored.

7. Do not overfill the fuel tank. After refueling, make sure the tank cap is closed properly and securely.

8. Be careful not to spill fuel when refueling. Fuel vapor or spilled fuel may ignite. If any fuel is spilled, make sure the area is dry before starting the engine.

9. Never run the engine in an enclosed or confined area. Exhaust contains poisonous carbon monoxide gas; exposure may cause loss of consciousness and may lead to death.

10. The muffler becomes very hot during operation and remains hot for a while after stopping the engine. Be careful not to touch the muffler while it is hot. To avoid severe burns or fire hazards, let the engine cool before transporting it or storing it indoors.

11. Never ship/transport sprayer with gasoline in the tank.

DO NOT use this equipment to spray water or acid.

Attention

Do not lift by cart handle when loading or unloading.Device is very heavy. Three-person lift is required.

1.4 Fueling (gas engine)

Gasoline is extremely flammable and is explosive under certain conditions.

Attention

Do not overfill the gas tank. Overfilling can cause the gas cap to become clogged with any particles in the gasoline which can cause a vaccum. Read the gas engine’s instruction manual for fueling instructions.

Fuel Specifications • Use automotive gasoline that has a pump octane number of

86 or higher, or that has a research octane number of 91 or higher. Use of a lower octane gasoline can cause persistent “pinging” or heavy “spark knock” (a metallic rapping noise) which, if severe, can lead to engine damage.

i If “spark knock” or “pinging” occurs at a steady engine speed under normal load, change brands of gasoline. If spark knock or pinging persists, consult an authorized dealer of the engine manufacturer. Failure to do so is considered misuse, and damage caused by misuse is not covered by the engine manufacturer’s limited warranty. Occasionally you may experience light spark knock while operating under heavy loads. This is no cause for concern, it simply means your engine is operating efficiently.

• Unleaded fuel produces fewer engine and spark plug deposits and extends the life of the exhaust system components.

• Never use stale or contaminated gasoline or an oil/gasoline mixture. Avoid getting dirt, dust, or water in the fuel tank.

Gasolines Containing AlcoholIf you decide to use a gasoline containing alcohol (gasohol), be sure its octane rating is at least as high as that recommended by the engine manufacturer. There are two types of “gasohol”: one containing ethanol, and the other containing methanol. Do not use gasohol that contains more than 10% ethanol. Do not use gasoline containing methanol (methyl or wood alcohol) that does not also contain co-solvents and corrosion inhibitors for methanol. Never use gasoline containing more than 5% methanol, even if it has co-solvents and corrosion inhibitors.

iFuel system damage or engine performance problems resulting from the use of fuels that contain alcohol is not covered under the warranty. The engine manufacturer cannot endorse the use of fuels containing methanol since evidence of their suitability is incomplete at this time.Before buying gasoline from an unfamiliar station, try to find out if the gasoline contains alcohol. If it does, confirm the type and percentage of alcohol used. If you notice any undesirable operating characteristics while using a gasoline that contains alcohol, or one that you think contains alcohol, switch to a gasoline that you know does not contain alcohol.

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2. General view of application2.1 ApplicationPriming and final coating of large areas, sealing, impregnation, construction sanitation, façade protection and renovation, rust protection and building protection, roof coating, roof sealing, concrete sanitation, as well as heavy corrosion protection.

Examples of objects to be sprayedLarge-scale construction sites, underground construction, cooling towers, bridges, sewage treatment plants and terraces.

2.2 Coating materialsProcessible coating materials

i Pay attention to the Airless quality of the coating materials to be processed.Latex paint, dispersion paints, fire protection and thick film materials, zinc dust and micaceous iron ore paints, Airless spray primer, sprayable glue, anti-corrosive agents, thick coating materials and bitumen-like coating materials. No other materials should be used for spraying without Titan’s approval.

FilteringIn spite of the high-pressure filter, filtering of the coating material is to be recommended in general (except when processing airless joint filler).Stir coating material before commencement of work.

i Make sure when stirring with motor-driven agitators that no air bubbles are stirred in. Air bubbles disturb when spraying and can, in fact, lead to interruption of operation.

ViscosityIt is possible to work with high-viscosity coating materials with the devices.If highly viscous coating materials cannot be sucked up, they must be diluted in accordance with the manufacturer’s instruction.

Two-component coating materialThe appropriate processing time must be adhered to exactly. Within this time rinse through and clean the unit meticulously with the appropriate cleaning agents.

Coating materials with sharp-edged additional materialsThese have a strong wear and tear effect on valves, high-pressure hose, spray gun and tip. The durability of these parts can be reduced appreciably through this.

3. Description of unit3.1 Airless processThe main area of application are thick layers of highly viscous coating material for large areas and a high consumption of material.A piston pump takes in the coating material by suction and conveys it to the tip. Pressed through the tip at a pressure of up to a maximum of 3300-3600 PSI (228-248 bar, 24.4-24.8 MPa), the coating material is atomised. This high pressure has the effect of micro fine atomisation of the coating material.As no air is used in this process, it is described as an AIRLESS process.This method of spraying has the advantages of finest atomisation, cloudless operation and a smooth, bubble-free surface. As well as these, the advantages of the speed of work and convenience must be mentioned.

3.2 Functioning of the unitThe following section contains a brief description of the technical construction for better understanding of the function.TITAN PowrTwin Plus (PT) are high-pressure spraying units driven by either a gasoline engine or electric motor.The gasoline engine or electric motor (fig. 1, item 1) drives the hydraulic pump (3) by means of a V-belt which is under the belt cover (2). Hydraulic oil flows to the hydraulic motor (4) and then moves the piston up and down in the material feed pump (5).The inlet valve is opened automatically by the upwards movement of the piston. The outlet valve is opened when the piston moves downward.The coating material flows under high pressure through the high-pressure hose to the spray gun. When the coating material exits from the tip it atomises.The pressure control valve (6) controls the volume and the operating pressure of the coating material.

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3.3 System diagram - gasoline PT units

1 Extractable handle 2 Hydraulic motor 3 Oil cup for separating oil (separating oil prevents increased

wear and tear of the packings) 4 Pressure control knob 5 Relief valve handle: Turn left for circulation k Turn right for spray p 6 High-pressure filter

7 High-pressure hose outlet 8 V-belt under the belt cover 9 Bleed hose 10 Ball valve: horizontal position – hydraulic motor switched off vertical position – hydraulic motor switched on 11 Suction tube 12 Oil measuring stick 13 Gasoline engine

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3.4 System diagram - electric PT units

1 Extractable handle 2 Hydraulic motor 3 Oil cup for separating oil (separating oil prevents increased

wear and tear of the packings) 4 Pressure control knob 5 Relief valve handle: Turn left for circulation k Turn right for spray p 6 High-pressure filter 7 High-pressure hose outlet 8 V-belt under the belt cover

9 Bleed hose 10 Ball valve: horizontal position – hydraulic motor switched off vertical position – hydraulic motor switched on 11 Suction tube 12 Oil measuring stick 13 Electric motor (230V) 14 ON/OFF switch 15 Control lamp that shows unit operational 16 Power Cord

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PT4900 Plus (230V)

PT4900 Plus (gas)

PT6900 Plus PT8900 Plus PT12000 Plus

Gasoline engine, power

Honda -------- 163cc, 4.8 Hp 163cc, 4.8 Hp 196cc, 5.5 Hp 270cc, 8.5 Hp

Fuel Capacity

-------- 0.95 US gal (3.6 l) 0.83 US gal (3.1 l) 0.83 US gal (3.1 l) 1.6 US gal (6.06 l)

Voltage

230 V~, 50 Hz -------- -------- -------- --------

Capacity

2.6 kW -------- -------- -------- --------

Power Cord

3 x 2.5 mm2 – 6 m -------- -------- -------- --------

Fuse Protection

16 A -------- -------- -------- --------

Max. operating pressure

22.8 MPa (228 bar, 3300 PSI) 24.8 MPa (248 bar, 3600 PSI)

Max. sound pressure level

80 dB (A)* 92 dB (A)* 98 dB (A)*

Max. size of tip with a spray gun

1-gun 0.031” – 0.79 mm 0.037” – 0.94 mm 0.050” – 1.27 mm 0.054” – 1.37 mm 0.059” – 1.50 mm

2-gun 0.028” – 0.71 mm 0.028” – 0.71 mm 0.033” – 0.84 mm 0.038” – 0.96 mm 0.040” – 1.01 mm

3-gun 0.022” – 0.56 mm 0.022” – 0.56 mm 0.023” – 0.58 mm 0.032” – 0.81 mm 0.034” – 0.86 mm

4-gun -------- -------- 0.019” – 0.48 mm 0.028” – 0.71 mm 0.030” – 0.76 mm

5-gun -------- -------- -------- 0.024” – 0.61 mm 0.026” – 0.66 mm

6-gun -------- -------- -------- -------- 0.024” – 0.61 mm

Max. volume flow

1.1 gal (4.2 l)/min 1.5 gal (5.7 l)/min 2.35 gal (8.9 l)/min 2.5 gal (9.5 l)/min 3.15 gal (11.9 l)/min

Weight

139 lbs. (63 kg) 132 lbs. (60 kg) 139 lbs. (63 kg) 154 lbs. (70 kg) 183 lbs. (83 kg)

Max. viscosity

50.000 mPa·s 65.000 mPa·s

Dimensions L x W x H

37.2” x 26.8” x 35” (946 x 680 x 890 mm) 42.5” x 27” x 31” (1080 x 686 x 866 mm)46” x 27” x 31” (1168 x 686 x

866 mm)

Max. temperature of the coating material

109ºF (43° C)

Filter insert (standard equipment)

50 mesh, 18 in2

Hydraulic oil filling quantity

5.9 l (1.56 gal) CoolFlo

Max. tire pressure

0.2 MPa (2 bar, 30 PSI)

Special high-pressure hose

DN 6 mm, 15 m (50’ x 1/4”), connection thread NPSM 1/4

* Place of measurement: 1 m distance from unit and 1.60 m above reverberant floor, 120 bar (12 MPa) operating pressure.

3.5 Technical data for PT units

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3.6 Airless Spray Tip Recommendation Chart

Viscosity Filter Mesh Coating Orifice Range Synergy™ (Fine Finish)

Light 100-150 Varnishes .009 - .011 .008 - .010

Lacquer Finishes (clear) .009 - .011 .008 - .010

Sanding Sealers .009 - .011 .008 - .010

Shellac (clear) .009 - .013 .008 - .012

Transparent Stain .011 - .013 .010 - .012

Water Sealers (clear) .011 - .013 .010 - .012

Medium 60-100 Solid Stains .013 - .015

Exterior House Paints .013 - .017

Interior Wall Paints .013 - .017

Interior & Exterior Primers .017 - .019

Heavy 30-60 Commercial Grade

Architectural Coatings .017 - .019

Interior Wall Paints .017 - .019

Interior Wall Primers .017 - .019

Dry Fall (quick dry) .019 - .023

One Coat, Primer-Finish Paints .019 - .023

Extra Heavy 0 Elastomerics .021 - .031

Pigmented Waterproofers .021 - .027

Block Filler .025 - .031

Orifice sizes recommended on this chart are based on fan widths between 8 inches (20 cm) and 12 inches (30 cm)

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4. Operation

This equipment produces a fluid stream at extremely high pressure. Read and understand the warnings in the Safety Precautions section at the front of this manual before operating this equipment.

4.1 Setup 1. Make sure the siphon hose (fig. 4, 1) is connected to the fluid

section (2) and the bleed hose (3) is connected to the bleed valve (4). They each have factory installed PTFE tape on the male end of the hoses and should be wrench tight.

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2. Attach a minimum of 15m of nylon airless spray hose to the sprayer. Do not use PTFE tape or thread sealant on the spray hose connection.

3. Attach an airless spray gun to the spray hose. Do not attach the tip to the spray gun yet. Remove the tip if it is already attached.

a. To use two guns, remove the plug from the second gun outlet on the filter assembly. Connect a hose and gun to the outlet.

i For multiple gun operation, connect a multiple gun manifold to the single gun outlet. Connect a hose and gun to each outlet. Make sure the second gun outlet remains plugged. See “Technical Data”, Section 3.5 to determine number of guns and maximum spray tip sizes.

4. Fill the oil cup 1/2 full with Piston Lube (P/N 314-480). This extends packing life.

Attention

Piston Lube prevents increased wear and tear to the packings.

5. Check the hydraulic fluid level daily before starting the sprayer. The hydraulic fluid level should be at the “Full” mark on the dipstick. Refer to the Maintenance section of this manual for hydraulic system maintenance instructions.

Attention

Use of Titan’s Coolflo™ Hydraulic Fluid (P/N 430-361) is mandatory in the hydraulic system. Do not use any other hydraulic fluid. Use of any other hydraulic fluid may seriously damage the hydraulic system and will void the warranty.

6. For gas models, check the engine oil level daily before starting the sprayer. The gasoline engine oil level is determined by the engine manufacturer. Refer to the engine manufacturer’s service manual supplied with this sprayer.

7. For electric models, use a 20 amp service outlet. Always locate the electric model within 10 to 15 feet of the service outlet. Use a short electric cable and a long paint hose. Any extension cord will create some voltage drop. If an extension cord is necessary, use only a grounded 3-wire #12 extension cord.

8. Make sure the sprayer is earthed. All sprayers are equipped with a earthing lug. An earthing cable (not supplied) should be used to connect the sprayer to a true earth ground. Check your local electrical regulations for detailed earthing instructions.

Proper earthing is important. This applies to both gas and electric powered models. The passage of some materials through the nylon fluid hose will build up a static electric charge, which if discharged, could ignite solvent vapors present and create an explosion.

9. Strain all paints with a nylon strainer to ensure trouble free operation and freedom from frequent cleaning of the inlet screen and gun filter.

10. Make sure the spray area is well ventilated to prevent hazardous operation with volatile solvents or exhaust fumes.

If lacquer or other flammable materials are to be sprayed, ALWAYS locate the sprayer outside the immediate spraying area. Failure to do so may cause an explosion.

11. Locate the sprayer outside the immediate spraying area to avoid clogged air intake of the engine or electric motor with overspray.

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4.2 Preparing a New SprayerIf this unit is new, it is shipped with test fluid in the fluid section to prevent corrosion during shipment and storage. This fluid must be thoroughly cleaned out of the system with mineral spirits before you begin spraying.

Attention

Always keep the trigger lock on the spray gun in the locked position while preparing the system.

1. Place the siphon tube into a container of mineral spirits. 2. Place the bleed hose into a metal waste container. 3. Turn the pressure control knob fully counterclockwise to its

lowest pressure setting (fig 7, 1). 4. Open the hydraulic shut-off valve (2) located on the hydraulic

pressure hose. The handle should be in line with the hose. 5. Open the bleed valve (3) by turning it fully counterclockwise.

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6. Start the engine or turn on the electric motor. a. To start the gas engine (fig. 8), • move the fuel valve lever (2) to the open position, • move the throttle lever (3) to its middle point, • move the choke lever (4) to the closed position for a cold

engine or to the open position for a warm engine, • turn the engine switch (1) to the ON position, and • pull the starter rope (5) briskly until the engine starts. b. To start the electric motor, move the ON/OFF switch to the ON

position.

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7. Turn the pressure control knob (fig. 7, 1) clockwise approximately 1/3 of the way down to increase pressure until the sprayer cycles evenly and solvent flows freely from the bleed hose.

8. Allow the sprayer to run for 15–30 seconds to flush the test fluid out through the bleed hose and into the waste container.

9. Turn off the sprayer. a. To turn off the gas engine, • set the pressure to minimum by turning the pressure control

knob fully counterclockwise, • move the throttle lever to the slow position, and • turn the engine switch to the OFF position. b. To turn off the electric motor, • set the pressure to minimum by turning the pressure control

knob fully counterclockwise, • move the ON/OFF switch to the OFF position.

Earth the gun by holding it against the edge of the metal container while flushing. Failure to do so may lead to a static electric discharge, which may cause a fire.

14. Trigger the gun into the metal waste container until the old solvent is gone and fresh solvent is coming out of the gun.

15. Lock the gun by turning the gun trigger lock to the locked position (fig 10).

16. Set down the gun and increase the pressure by turning the pressure control knob slowly clockwise to its highest setting.

17. Check the entire system for leaks. If leaks occur, turn the sprayer off and follow the “Pressure Relief Procedure” in this manual before tightening any fittings or hoses.

18. Follow the “Pressure Relief Procedure” (section 4.5) in this manual before changing from solvent to paint.

Be sure to follow the Pressure Relief Procedure when shutting the unit down for any purpose, including servicing or adjusting any part of the spray system, changing or cleaning spray tips, or preparing for cleanup.

4.3 Preparing to PaintBefore painting, it is important to make sure that the fluid in the system is compatible with the paint that is going to be used.

i Incompatible fluids and paint may cause the valves to become stuck closed, which would require disassembly and cleaning of the sprayer’s fluid section.

Attention

Always keep the trigger lock on the spray gun in the locked position while preparing the system.

1. Place the siphon tube into a container of the appropriate solvent for the material being sprayed.

i If you are spraying a water-based latex, flush with warm, clean water. If you are using any other material, check with the material manufacturer for a compatible solvent.

2. Place the bleed hose into a metal waste container. 3. Turn the pressure control knob fully counterclockwise to its

lowest pressure setting (fig 7, 1). 4. Open the hydraulic shut-off valve (2) located on the hydraulic

pressure hose. The handle should be in line with the hose. 5. Open the bleed valve (3) by turning it fully counterclockwise. 6. Start the engine or turn on the electric motor. a. To start the gas engine (fig. 8), • move the fuel valve lever (2) to the open position, • move the throttle lever (3) to its middle point, • move the choke lever (4) to the closed position for a cold

engine or to the open position for a warm engine, • turn the engine switch (1) to the ON position, and • pull the starter rope (5) briskly until the engine starts. b. To start the electric motor, move the ON/OFF switch to the ON

position. 7. Turn the pressure control knob (1) clockwise approximately

1/3 of the way down to increase pressure until the sprayer cycles evenly and solvent flows freely from the bleed hose.

8. Allow the sprayer to run for 15–30 seconds to flush the test fluid out through the bleed hose and into the waste container.

9. Turn off the sprayer. a. To turn off the gas engine, • set the pressure to minimum by turning the pressure control

knob fully counterclockwise, • move the throttle lever to the slow position, and • turn the engine switch to the OFF position. b. To turn off the electric motor, • set the pressure to minimum by turning the pressure control

knob fully counterclockwise, • move the ON/OFF switch to the OFF position.

i Make sure that the spray gun does not have a tip or tip guard installed. 10. Close the bleed valve by turning it fully clockwise. 11. Start the engine or turn on the electric motor. 12. Turn the pressure control knob clockwise approximately 1/3

of the way down to increase pressure. 13. Unlock the gun by turning the gun trigger lock to the

unlocked position.

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4.4 Painting 1. Place the siphon hose into a container of paint. 2. Place the bleed hose into a metal waste container. 3. Turn the pressure control knob fully counterclockwise to its

lowest pressure setting (fig 7, 1). 4. Open the hydraulic shut-off valve (2) located on the hydraulic

pressure hose. The handle should be in line with the hose. 5. Open the bleed valve (3) by turning it fully counterclockwise. 6. Start the engine or turn on the electric motor. a. To start the gas engine (fig. 8), • move the fuel valve lever (2) to the open position, • move the throttle lever (3) to its middle point, • move the choke lever (4) to the closed position for a cold

engine or to the open position for a warm engine, • turn the engine switch (1) to the ON position, and • pull the starter rope (5) briskly until the engine starts. b. To start the electric motor, move the ON/OFF switch to the ON

position. 7. Turn the pressure control knob (1) clockwise approximately

1/3 of the way down to increase pressure until the sprayer cycles evenly and solvent flows freely from the bleed hose.

8. Turn off the sprayer. a. To turn off the gas engine, • set the pressure to minimum by turning the pressure control

knob fully counterclockwise, • move the throttle lever to the slow position, and • turn the engine switch to the OFF position. b. To turn off the electric motor, • set the pressure to minimum by turning the pressure control

knob fully counterclockwise, • move the ON/OFF switch to the OFF position. 9. Remove the bleed hose from the waste container and place it

into the container of paint. 10. Close the bleed valve by turning it fully clockwise. 11. Start the engine or turn on the electric motor. 12. Turn the pressure control knob clockwise approximately 1/3

of the way down to increase pressure. 13. Unlock the gun by turning the gun trigger lock to the

unlocked position.

Earth the gun by holding it against the edge of the metal container while flushing. Failure to do so may lead to a static electric discharge, which may cause a fire.

14. Trigger the gun into the metal waste container until all air and solvent is flushed from the spray hose and paint is flowing freely from the gun.

15. Lock the gun by turning the gun trigger lock to the locked position (fig 10).

16. Turn off the sprayer. 17. Attach tip guard and tip to the gun as instructed by the tip

guard or tip manuals.

POSSIBLE INJECTION HAZARD. Do not spray without the tip guard in place. Never trigger the gun unless the tip is in either the spray or the unclog position. Always engage the gun trigger lock before removing, replacing or cleaning tip.

18. Start the engine or turn on the electric motor.

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GB Operation

19. Increase the pressure by turning the pressure control knob slowly clockwise and test the spray pattern on a piece of cardboard. Adjust the pressure control knob until the spray from the gun is completely atomized.

i Turning the pressure up higher than needed to atomize the paint will cause premature tip wear and additional overspray.

4.5 Pressure Relief Procedure

Be sure to follow the Pressure Relief Procedure when shutting the unit down for any purpose, including servicing or adjusting any part of the spray system, changing or cleaning spray nozzles, or preparing for cleanup.

1. Lock the spray gun by turning the gun trigger lock to the locked position.

2. Turn off the sprayer. a. To turn off the gas engine, • set the pressure to minimum by turning the pressure control

knob fully counterclockwise, • move the throttle lever to the slow position, and • turn the engine switch to the OFF position. b. To turn off the electric motor, • set the pressure to minimum by turning the pressure control

knob fully counterclockwise, • move the ON/OFF switch to the OFF position. 3. Close the hydraulic shut-off valve on the hydraulic pressure

hose. 4. Unlock the gun by turning the gun trigger lock to the

unlocked position. 5. Hold the metal part of the gun firmly to the side of a metal

waste container to earth the gun and avoid a build up of static electricity.

6. Trigger the gun to remove any pressure that may still be in the hose.

7. Lock the gun by turning the gun trigger lock to the locked position.

8. Place the bleed hose into the metal waste container. 9. Open the bleed valve by turning it fully counterclockwise.

14 PowrTwin Plus

GBCleanup

5. Cleanup

Attention

The sprayer, hose, and gun should be cleaned thoroughly after daily use. Failure to do so permits material to build up, seriously affecting the performance of the unit.

Always spray at minimum pressure with the gun nozzle tip removed when using mineral spirits or any other solvent to clean the sprayer, hose, or gun. Static electricity buildup may result in a fire or explosion in the presence of flammable vapors.

5.1 Special cleanup instructions for use with flammable solvents

• Always flush spray gun preferably outside and at least one hose length from spray pump.

• If collecting flushed solvents in a one gallon metal container, place it into an empty five gallon container, then flush solvents.

• Area must be free of flammable vapors. • Follow all cleanup instructions.

5.2 Cleaning the sprayer 1. Follow the “Pressure Relief Procedure” found in the Operation

section of this manual, section 4.5. 2. Remove the gun tip and tip guard and clean with a brush

using the appropriate solvent. 3. Place the siphon tube into a container of the appropriate

solvent.

Attention

Use only compatible solvents when cleaning out oil based enamels, lacquers, coal tar, and epoxies. Check with the fluid manufacturer for the recommended solvent.

4. Place the bleed hose into a metal waste container. 5. Set the pressure to minimum by turning the pressure control

knob (1) fully counterclockwise. 6. Open the hydraulic shut-off valve located on the hydraulic

pressure hose (2). The handle should be in line with the hose. 7. Open the bleed valve (3) by rotating the bleed valve handle

fully counterclockwise.

13

2

8. Start the engine or turn on the electric motor. 9. Allow the solvent to circulate through the sprayer and

flush the paint out of the bleed hose into the metal waste container.

10. Turn off the sprayer. 11. Close the bleed valve by rotating the bleed valve handle fully

clockwise.

12. Start the engine or turn on the electric motor.

Earth the gun by holding it against the edge of the metal container while flushing. Failure to do so may lead to a static electric discharge, which may cause a fire.

13. Trigger the gun into the metal waste container until the paint is flushed out of the hose and solvent is coming out of the gun.

14. Continue to trigger the spray gun into the waste container until the solvent coming out of the gun is clean.

i For long-term or cold weather storage, pump mineral sprits through the entire system. 15. Follow the “Pressure Relief Procedure” found in the Operation

section of this manual. 16. Store the sprayer in a clean, dry area.

Attention

Do not store the sprayer under pressure.

5.3 Cleaning a Clogged Tip 1. Follow the “Pressure Relief Procedure” in the Operation

section of this manual. 2. If the tip clogs, rotate the tip handle 180° until the arrow on

the handle is facing the opposite of the spray direction and the handle clicks in the reverse position.

3. Trigger the gun once so that the pressure can blow the clog out. NEVER use the tip in the reverse position for more than ONE trigger pull at a time. This procedure can be repeated until the tip is free of clogging.

The flow from the spray tip is at very high pressure. Contact with any body part may be dangerous. Do not place finger on gun outlet. Do not point the gun at any person. Never operate the spray gun without the proper tip guard.

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6. Maintenance

Before proceeding, follow the Pressure Relief Procedure outlined previously in this manual. Additionally, follow all other warnings to reduce the risk of an injection injury, injury from moving parts or electric shock. Always unplug the sprayer before servicing!

6.1 Daily MaintenanceTwo daily procedures are required for routine operator maintenance on this sprayer: A. Lubricating the upper packings. B. Cleaning the filter screen

A) Lubricating the Upper Packings 1. Clean out the paint that has seeped past the upper packings

into the packing oil reservoir (fig. 13, item 1) above the fluid section.

2. Fill the packing oil reservoir 1/2 full with Piston Lube (P/N 314-480) supplied by the factory. This will extend packing life.

1

i Do not over-fill the reservoir so that it overflows and drips into the paint.

B) Cleaning the Filter Screen 1. The filter screen will clog and must be cleaned at least once a

day. 2. Loosen the hex nut (fig. 14, item 1) that secures the filter

screen to the siphon tube. 3. Remove the filter screen (2) from the bottom of the siphon

tube. 4. Clean thoroughly with the appropriate solvent.

21

6.2 Maintaining the Filter AssemblyClean the filter regularly. Dirty or clogged filters can greatly reduce filtering ability and cause a number of system problems including poor spray patterns, clogged spray tips, etc.

Cleaning (Fig. 15)To clean the filter, perform the following procedure. 1. Follow the “Pressure Relief Procedure” found in the Operation

section of this manual. 2. Remove the filter cap assembly (1) and spring (2). 3. Pull the filter element with ball straight (3) out of the filter

body (4). 4. Clean inside the filter body, filter element with ball, and filter

cap assembly using the appropriate solvent.

i Use care in handling parts as dirt, debris, scratches, or nicks may prevent o-rings or gaskets from sealing.This filter element filters from the inside out. Be sure to clean the filter element thoroughly on the inside. Soak in solvent to loosen hardened paint or replace.

1

3

7

8

56

4

2

Inspection (Fig. 15)Inspect all parts of the filter assembly before reassembly. 1. Inspect the ball inside the filter element. If the ball has

pressure cuts or scratches, replace the filter element. a. If the ball is cut, remove the PTFE o-ring (5) using an o-ring pick

and remove the carbide seat (6). b. Check the seat for nicks or grooves. If the seat is damaged,

replace.

i Removal of the PTFE o-ring will damage the o-ring and require replacement. 2. Remove the spring (2) from the spring guide on the filter cap. a. Measure the length of the spring uncompressed. If it measures

less than 3/4” from end to end, replace. b. Push the spring back onto the spring guide until it “snaps” back

into position. 3. Inspect the two PTFE gaskets (7,8) and the PTFE o-ring (5) for

deformity, nicks, or cuts. Replace, if needed.

i The PTFE gaskets, PTFE o-ring, and spring are packaged in Filter Service Kit P/N 930-050.

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GBMaintenance

Reassembly (Fig. 15)After cleaning and inspecting all parts, reassemble the filter. 1. Place the carbide seat (6) into the filter body (4). Make sure

the beveled side of the seat is facing up. 2. Place the PTFE o-ring (5) into the groove on the outer

diameter of the carbide seat (6). 3. Place the filter element with ball (3) into the filter body (4).

i The top and bottom of the filter element with ball are identical. 4. Push the spring (2) back onto the spring guide of the filter cap

(1) until it “snaps” back into position, if not already done. 5. Place the thin PTFE gasket (8) onto the step at the top of the

filter body (4). 6. Place the thick PTFE gasket (7) onto the top of the thin gasket

(8). 7. Tighten the filter cap assembly (1) onto the filter body (4).

1

3

7

8

56

4

2

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GB Maintenance

6.3 Maintaining the Hydraulic System

Attention

Use of Titan’s Coolflo™ Hydraulic Fluid is mandatory in the PowrTwin Plus hydraulic system. Do not use any other hydraulic fluid. Use of any other hydraulic fluid may seriously damage the hydraulic system and will void the warranty.

1. Check the hydraulic fluid daily. It should be at the “Full” mark (fig. 16, item 1) on the dipstick (2). If it is low, add only Titan Coolflo™ Hydraulic Fluid (P/N 430-361). Never add or change hydraulic fluid except in a clean, dust-free area. Contamination of the hydraulic fluid will shorten hydraulic pump life and may void warranty.

1

2

3

2. Change the hydraulic fluid every twelve months. Drain the old fluid from the tank and fill with 6.25 quarts of hydraulic fluid. Start the sprayer at just enough pressure to operate the fluid section. Run the sprayer at this low pressure for at least 5 minutes. This removes air from the system. Check the fluid level after this procedure. Do not over-fill.

i When replacing the hydraulic filter (3) during a fluid change, it may be necessary to add up to one additional quart of hydraulic fluid.

3. The hydraulic system has an external, replaceable hydraulic filter. Change the filter every twelve months.

4. The hydraulic pump should not be serviced in the field. If service on the hydraulic pump is required, it must be returned to Titan.

6.4 Maintaining the Fluid SectionIf the sprayer is going to be out of service for an extended period of time, it is recommended that following cleanup, a kerosene and oil mixture be introduced as a preservative. Packings may tend to dry out from lack of use. This is particularly true of the upper packing set for which upper packing lubricant Piston Lube (P/N 314-480) is recommended in normal usage. If the sprayer has been out of service for an extended period of time, it may be necessary to prime the pump with solvent. It is extremely important that the threads on the siphon hose coupling are properly sealed. Any air leakage will produce erratic operation of the sprayer and may damage the system. The up and the down strokes should be approximately equal in time (one should not be faster than the other). A fast up or down stroke may indicate air in the system or malfunctioning valve or seats (see the Troubleshooting section).

6.5 Basic Engine Maintenance (gas engine) • For detailed engine maintenance and technical specifications

refer to the separate gasoline engine manual. • All service to the engine should be performed by a dealer

authorized by the engine manufacturer. • Use a premium quality motor oil. 10W30 is recommended for

general all temperature use. Other viscosities may be required in other climates.

• Use only a (NGK) BR-6HS (PT4900), or (NGK) BP6ES / BPR6E spark plug (PT6900/PT8900/PT12000). Gap the plug to 0.028 to 0.031 In. (0.7 to 0.8 mm) Always use a spark plug wrench.

Daily 1. Check engine oil level, and fill as necessary. 2. Check gasoline level, and fill as necessary.

Always follow the fueling procedure outlined earlier in this manual.

First 20 Hours 1. Change engine oil.

Every 100 Hours 1. Change engine oil. 2. Clean the sediment cup. 3. Clean and re-gap the spark plug. 4. Clean the spark arrestor.

Weekly 1. Remove the air filter cover and clean the element. In very

dusty environments, check the filter daily. Replace the element as needed. Replacement elements can be purchased from your local engine manufacturer dealer.

Engine Operation and Service 1. Clean and oil air filter pad on gasoline engine every 25 hours

or once weekly. Do not permit the air intake screen around the fly wheel of the gas engine to load up with paint or trash. Clean it regularly. The service life and efficiency of the gas engine model depends upon keeping the gasoline engine running properly. Change the oil in the engine every 100 hours. Failure to observe this may result in engine overheating. Consult the engine manufacturer’s service manual provided.

2. To conserve fuel, service life, and efficiency of the sprayer, always operate the gasoline engine at the lowest RPM at which it runs smoothly without laboring and delivers the amount required for the particular painting operation. Higher RPM does not produce higher working pressure. The gasoline engine is connected to the hydraulic pump by a pulley combination designed to produce full paint delivery at maximum RPM.

3. The warranty on gasoline engines or electric motors is limited to the original manufacturer.

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GBMaintenance

6.6 Replacing the Motor Brushes (optional 120V electric motor)

The 120V electric Convertokit is available for separate purchase. Perform this procedure using Motor Brush Kit P/N 978-050. The kit consists of two brushes, two springs, and two clips.

i Brushes should be replaced when they are worn to less than 1/2 inch. Check and replace both brushes at the same time.

1. Remove both inspection covers (1) on the motor.

1

2. Push in the spring clip (2) to unhook it, then pull it out. 3. Loosen the terminal screw (3). Pull the brush lead (4) away,

but leave the motor lead in place. Remove the brush and spring.

3

2

4

4. Inspect the commutator (5) for burning, excessive pitting or gouging. A black color on the commutator is normal.

5

5. Install the new brush (6) so its lead slides in the long slot of the brush holder (7). Push the terminal under the terminal screw washer (8). Ensure the motor lead is still connected at the screw. Tighten the screw.

6. Place the spring (9) on the brush (6) as shown above. Push in and hook the spring clip (2). Repeat this procedure for the other side.

6

7

8

92

7. Reinstall both inspection covers.

If electric motor overloads and stops running, IMMEDIATELY turn the motor off and follow the Pressure Relief Procedure in the Cleanup section of this manual. Wait until the motor cools (approximately 30 minutes). Then push in the bubble top, manual reset button, turn the motor on and pressurize the system.

5 6

1

2

4

3

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6.7 Replacing the Belt (Fig. 21)

Before replacing the belt on your unit, make sure you have performed the “Pressure Relief Procedure” as illustrated in the Operation section of this manual. DO NOT attempt this repair while the unit is running.

i The graphics below show a unit with a gas engine. All instructions given in this section will apply to both gas engine models and electric motor models except where noted.

1. Loosen the bolt (1) on the front of the belt guard. Lift open the front end of the belt guard (2) so that the front end of the belt (3) is exposed.

2. Gently lift the front end of the gas engine / electric motor. This will loosen the tension on the belt and make it easier to remove.

PINCH HAZARD. Make sure your fingers remain clear of the gas engine / electric motor mounting plate.

BURN HAZARD. Make sure the gas engine has had time to sufficiently cool before touching it.

3. While the gas engine / electric motor is lifted up, remove the belt from the front (4) and rear (5) pulleys.

4. Install the new belt: a. Insert the belt into the fixed section of the belt guard (6). Loop

the belt over the rear pulley (5) until the belt engages the pulley groove.

b. Gently lift the front end of the gas engine / electric motor. c. With the front end of the gas engine / electric motor lifted, loop

the other end of the belt around the front pulley (4). d. Gently set the the gas engine / electric motor down. The

weight of the gas engine / electric motor will create tension in the belt and prevent it from coming off.

Attention

Make sure the belt is not pinched or twisted in any way once you have set the gas engine / electric motor back into place.

e. Close the belt guard (2) and tighten the belt guard bolt (1).

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6.8 Servicing the Hydraulic Motor (Fig. 22)

123

567

4

8

14

15

16

17

18

19

9

12

13

10

11

2829

9

30

31

20

21

26

22

23

24

25

21

(B)

(A)

i Refer to the ”SAE O-Ring Fitting Installation” procedure at the end of this section for installation instructions for item 22 and 24.

Perform this procedure using the necessary parts from Motor Service Kit — Minor (P/N 235-050). If the hydraulic motor is operable, start the machine and jog the piston rod (19) into its top position.

i Servicing of the hydraulic motor should be carried out in a clean, dust free area only. Any dust or metallic particles left in the motor or entering it on reassembly may damage the critical parts and affect its service life and warranty. All parts should be inspected for absolute cleanliness.

Disassembling the Hydraulic Motor 1. Disconnect the pressure hose assembly (B) from the elbow on

the back of the hydraulic pump. 2. Remove the two mounting screws and two lock washers that

attach the motor/pump assembly to the cart. 3. Place the motor/pump assembly in a vise, holding it securely

by the motor/pump block (31). 4. Remove cylinder head plug (1). 5. Loosen lock ring (28) with a spanner wrench and unthread

tube retaining nut on tee (24). Loosen tube retaining nut on elbow (22). Slide the nut down. Remove motor tube assembly (23). Slowly unthread cylinder head (8) and Iift it just high enough above the cylinder (29) to reach the valve rod assembly (18) with vise grip pliers.

6. The piston rod (19) should be near the top of its stroke for disassembly. It may be necessary to use a wood or nylon driver to push the piston rod up to its top position.

7. Grip the valve rod securely with vise grip pliers and then remove the FlexLoc nut (3) from the top of the valve rod assembly (18). Be careful that spool (10) does not fall. The cylinder head (8) can now be lifted off. Unthread the cylinder (29) from the motor/pump block (31).

i An extra lock ring (28) can be used to jam the two lock rings together on the cylinder and a pipe wrench can be used to unthread the cylinder (29) from the motor/pump block.

8. To remove the connecting pin (Fig. 23, 1), slide the retaining ring (2) down with a small screwdriver, and then push the connecting pin out.

1

2

9. Remove the piston rod assembly from the motor/pump block (31).

10. Remove rod seal (30), being extremely careful not to scratch the seal groove in the motor/pump block (31).

11. Place the piston retainer screw (14) on the piston rod assembly in a vise. Slide a long bar through the hole at the base of the piston rod for leverage, and unthread the piston rod from the piston retainer screw.

12. Remove piston (19) and lift out valve rod assembly (18). 13. Remove piston seal (16) and o-ring (17).

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GB Maintenance

14. Remove trip retainers (4), trip springs (6), and balls (7) from cylinder head (8). Remove o-rings (5) from trip retainers.

15. Remove retaining ring (13) and sleeve retainer (12). Gently tap spool/sleeve set (10) out of cylinder head (8) using a wood or nylon rod.

16. Inspect piston rod (19) and cylinder (29) for wear, scratches, and dents. Replace if damaged.

17. Inspect spool valve (10) for wear. Replace if necessary. spool valve should move smoothly and freely with no force by holding in a vertical position. If it does not, it can cause the motor to stall.

Reassembling the Hydraulic Motor 1. Separate spool/sleeve set (10). Place o-rings (11) onto sleeve.

Lubricate o-rings with hydraulic oil. Gently push the sleeve into cylinder head (8) with the flatter side of the sleeve facing out. Use a nylon rod to tap sleeve down until it reaches its full depth. Do not use any other type of tool that might damage or leave particles or residue on the sleeve. Install the spool through the top of the cylinder head, down into the sleeve.

Attention

Do not use Piston Lube pump packing lubricant. It is a solvent and will severely damage seals and O-Rings of the hydraulic motor.

2. Install o-rings (5) on trip retainers (4). Install trip retainer balls (7) followed by springs (6) which, when installed, will hold spool/sleeve set (10) in proper place for assembly.

3. Install sleeve retainer (12) followed by retainer ring (13) into cylinder head (8), which will hold valve sleeve in place. Install o-ring (9) in the o-ring groove of the cylinder head.

4. Replace rod seal (30) in motor/pump block (31). Be sure the open portion of the seal is facing upward (V). This seal requires no special tool.

5. Place piston rod (19) in vise. Inspect valve rod assembly (18) for any damage. Make sure the lock nut at the bottom of the valve rod assembly is secure. DO NOT remove. Then, place into piston rod as illustrated. Install o-ring (17), lubricating it well and replacing piston (15) onto piston rod (19). Put one drop of blue Loctite on the piston retainer screw (14). Tighten piston retainer screw until piston is locked into place. Check valve rod assembly for normal spring action at this time.

6. Install piston seal (16) with lips facing downward. Carefully install o-ring (17). Expand the ring and stretch it sufficiently for installation.

7. With motor/pump block (31) still in vise, install rod seal (30) by pushing it towards its groove with a properly sized blunt rod. Then complete installation with the fingers. No tool is necessary. Do not twist the seal.

8. Pre-lubricate the piston and valve rod assembly with Coolflo™ hydraulic fluid (P/N 430-361). Install piston rod (19) into motor/pump block (31) with a gently pushing and rotating motion to work the piston rod in through the rod seal (30).

i Inspect the bottom of piston rod (19) for nicks or sharp areas that could damage the piston seal during installation through the motor/pump block (31).

9. Replace the connecting rod pin and retainer ring. 10. Install o-ring (9) on cylinder wall. Lubricate ring and inner wall.

With the piston rod held firmly, the cylinder should be gently driven over the piston seal with a rubber mallet. Tightly thread the cylinder into motor/pump block (31).

11. Raise piston rod (19) to top position and thread lock ring (28) all the way up on upper threads of cylinder (29).

12. Pull valve rod assembly (18) up as far as it will travel and grasp it with vise grip pliers. Then install cylinder head (8), already assembled, over valve rod until the top threads of the valve rod pass through the top of the spool/sleeve set (10). The

valve rod threads must be clean and free of oil. Place one drop of blue Loctite on threads of flex lock nut (3) and thread nut onto valve rod to full tight position (do not over-tighten) while holding valve rod below with vise grip pliers.

13. Thread cylinder head (8) down onto the cylinder (29) and then back off just enough to reassemble hydraulic fittings and motor tube (23). Tighten lock ring with spanner wrench to hold cylinder head in position.

14. Install o-ring (2) onto cylinder head plug (1). Tighten.

Hydraulic Motor Cut-Away

Use blueLoctite onlock ring.

Usehydraulic

sealant.

Seal lip mustface up.

Torque �ex locknut to40 in.-lbs. (4.5 Nm).

Use blue Loctite.

Torque head plug to15 ft.-lbs. (22 Nm).Do not over-tighteno-ring seal.

Torque trip retainers to 8 ft.-lbs. (10.8 Nm).Do not over-tighteno-ring seal.

Torque pistonretainers to40 ft.-lbs. (55 Nm).Use red Loctite.

Seal lip mustface down.

Valve rod assemblyis factory set andpermanently Loctited.Do not disassemble.

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GBMaintenance

Attention

Use of non-Titan service parts may void warranty. Ask for original parts made by Titan for best services. This pump should receive a routine servicing after approximately 1,000 hours of use. Earlier servicing is required if there is excessive leakage from the top packing or if pump strokes become faster on one stroke or the other. The use of Titan Piston Lube (P/N 314-480) is recommended as an upper packing lubricant. Do not substitute oil, water, or solvent for an upper packing lubricant.

i Numbers in parentheses refer to the item numbers in the fluid section illustrations. If there are two numbers, the first number represents the item number for the PT4900 Plus and the second number represents the item number for the PT6900 Plus / PT8900 Plus / PT12000 Plus.

Disassembling the Fluid Section 1a. Remove the siphon hose assembly. Unthread the foot valve

housing (20,21) and the pump cylinder (14) with a strap wrench.

i If the pump cylinder (14) cannot be removed with a strap wrench, use the jam nut (23, 22) to remove it from the pump housing.

1b. Loosen the jam nut (23, 22) on the cylinder until it bottoms out on the cylinder threads. Place a wrench on the flats of the jam nut and turn the wrench counterclockwise to loosen the cylinder.

2. Slide the retainer ring (1) up with a small screwdriver, then push the connecting pin (2) out.

3. Pull the displacement rod (6) through the lower cavity of the motor/pump block.

4. Remove the PTFE o-ring (3), upper packing spring (5), and upper packing set (4) from the motor/pump block.

5. Hold the displacement rod (6) in a vise by the flats at the top of the displacement rod and remove the outlet valve housing (13) with a wrench while holding the displacement rod horizontal with wooden support, if necessary. Remove the seal washer (12), outlet valve seat (11), outlet valve ball (10), outlet valve cage (9, PT6900/PT8900/PT12000) lower packing set (4), lower packing spring (9,8), sleeve (8, PT4900 only), and spring retainer (7, PT4900 only).

6. Using a 1/2” extension bar attached to a 1/2” drive ratchet, insert the end of the extension bar into the square opening of the foot valve cage (16,17) inside the foot valve housing

6.9 Servicing the Fluid Section

6

7

8

9

13

101112

14

23

15

16

171819

321

20

12

5

4

4

3

6

8

9

13

101112

14

22

15

16

17

181920

3

21

12

5

44

3

PT4900 Plus PT6900 Plus / PT8900 Plus / PT12000 Plus

PowrTwin Plus 23

GB Maintenance

(20,21). Unscrew and remove the foot valve cage along with the wave washer (21,16) from the foot valve housing.

7. Remove the PTFE o-ring (3), foot valve ball (17,18), foot valve seat (18,19), and seat o-ring (19,20) from the foot valve housing (20,21).

8. Remove the o-ring (15) from the pump cylinder (14)

Reassembling the Fluid Section

i Use PTFE tape on all threaded pipe connections. 1. Place a new seat o-ring (19,20) into the groove in the bottom

of the foot valve housing (20,21). 2. Inspect the foot valve seat (18,19) for wear. If one side is worn,

flip the seat to the unused side. If both sides are worn, install a new seat. Place the new or flipped seat (worn side down) into the bore at the bottom of the foot valve housing (20,21).

3. Place a new foot valve ball (17,18) onto the foot valve seat (18,19). Using a 1/2” extension bar attached to a 1/2” drive ratchet, insert the end of the extension bar into the square opening of the foot valve cage (16,17) and screw the foot valve cage into the foot valve housing (20,21). Torque the cage to 240 in./lbs. (20 ft./lbs.).

4. Place the wave washer (21, 16) on top of the foot valve cage (16,17).

5. Insert a new PTFE o-ring (3) into the groove of the foot valve housing (20,21). Lubricate the o-ring using oil or grease.

6. After soaking the leather packings in oil (preferably linseed oil), reassemble the lower packing set (4). Place the set onto the outlet valve housing (13) with the peak of the “V” packings pointing down toward the hex on the outlet valve housing.

iAll leather packings must be soaked in CoolFlo hydraulic oil for 15–20 minutes before installation. Soaking the packings too long will cause the packings to swell and create difficulty during reassembly.

7. Inspect the outlet valve seat (11) for wear. If one side is worn, flip the seat to the unused side. If both sides are worn, use a new seat. Insert the outlet valve cage (9, PT6900/PT8900/PT12000) outlet valve ball (10), new or flipped seat (worn side away from ball), and a new seal washer (12) into the displacement rod (6).

8. Clean the threads on the outlet valve housing (13) and coat the threads with blue Loctite #242. Make sure the Loctite is only on the threads.

9. Place the lower packing spring (9,8) onto the outlet valve housing (13) followed by the sleeve (8, PT4900 only) and spring retainer (7, PT4900 only).

10. Screw the displacement rod (6) and the outlet valve housing (13) together. Tighten in a vise to 600 in./lbs. (50 ft./lbs.).

11. Insert the PTFE o-ring (3) into the upper grove of the motor/pump block.

12. Insert the upper packing set (4) into the motor/pump block with the peak of the “V” packings pointing up toward the motor.

i The packings must be soaked in CoolFlo hydraulic oil before installation. 13. Place the upper packing spring (5) into the motor/pump block

with the small tapered end facing up toward the motor/pump block.

14. Insert the displacement rod (6) up through the upper packings in the motor/pump block.

15. Align the holes in the displacement rod (6) and the hydraulic piston rod and insert the connecting pin (2). Replace the retaining ring (1) over the connecting pin.

16. Thread the short threads of the pump cylinder (14) into the motor/pump block and tighten with a strap wrench.

17. Place the o-ring (15) onto the top groove of the pump cylinder (14).

18. Thread the foot valve housing (20,21) onto the pump cylinder (14), tighten with a strap wrench and then back off to align the siphon hose.

i It is not necessary to over-tighten the foot valve housing. O-ring seals perform sealing function without excessive tightening. Full thread engagement is sufficient. The foot valve housing may be rotated backward up to 1/2 turn from full engagement for convenient hose position.

For siphon hose attachment, it is critically important that the threads of the siphon hose fit snugly into the foot valve housing with the hose assembly couplings PTFE taped and sealed to prevent air leakage.

Fluid Section Cut-Away

Peaks of upperpackings must

face up.

Torque outletvalve housing

to 50 ft./lbs.(68 Nm).Use blue

Loctite.

Oil cup areafor piston lubepackinglubricant.

Peaks of lowerpackings mustface down.

Lubricate O-ring.

24 PowrTwin Plus

GBMaintenance

6.10 SAE O-Ring Fitting Installation 1. Pull washer and o-ring back as far as possible. 2. Lubricate o-ring (1) and entrance port (2).

1

2

3. Screw fitting in until washer pushes o-ring into entrance and sits flat against port. (Do not tighten! - only do this step hand tight to compress o-ring into port!)

4. Back fitting out no more than one complete turn to align as required.

5. Torque nut wrench tight holding backup on fitting (3). This should expose a recess gap (4) behind the nut which can act as an indicator that the fitting is assembled correctly. (This is a feature for a specific version of this fitting only - which screws into the cylinder head. Other fittings, as the ones which attach to the hydraulic pump, assemble the same but may not have the indicator.)

4

3

Attention

Avoid screwing in the fitting too far. This can cause the washer to bend, which will cause the O-ring to extrude.

Avoid leaving the fitting out too far. This can lead to the O-ring being cut on the threads of the fitting.

PowrTwin Plus 25

GB Troubleshooting

Problem A. Spitting gun

B. Gun will not shut off

C. Gun does not spray

Problem A. Pump delivers on upstroke only

or goes up slowly and down fast (commonly called downstroke dive)

B. Pump delivers on down stroke only or goes up fast and down slowly

C. Pump moves up and down fast, delivering material

D. Pump moves up and down slowly when spray gun is shut off

E. Not enough fluid pressure at gun

F. Pump chatters on up or down stroke

Cause 1. Air in system 2. Dirty gun 3. Needle assembly out of adjustment 4. Broken or chipped seat

1. Worn or broken needle & seat 2. Needle assembly out of adjustment 3. Dirty gun

1. No paint 2. Plugged filter or tip 3. Broken needle in gun

Cause 1. Lower foot valve ball is not seating due to

trash or wear 2. Material too viscous to siphon.

3. Air leaking in on siphon side or damaged siphon hose. Siphon may be too small for heavy material.

1. Upper ball is not seating due to trash or wear 2. Lower packing set is worn

1. Material container is empty or material is too thick to flow through siphon hose

2. Bottom ball stuck to foot valve seat 3. Siphon hose is kinked or loose

1. Loose connections. Bleed valve is open partially or bleed valve is worn. Lower packing seat is worn.

2. Upper and/or lower ball not seating

1. Spray tip is worn 2. Outlet filter or gun filter is clogged 3. Low voltage and/or inadequate amperage 4. Hose size or length is too small or too long

1. Solvent has caused upper packing to swell

Solution 1. Inspect connections for air leaks. 2. Disassemble and clean. 3. Inspect and adjust. 4. Inspect and replace.

1. Replace. 2. Adjust. 3. Clean.

1. Check fluid supply. 2. Clean. 3. Replace.

Solution 1. Remove foot valve assembly. Clean and inspect. Test

foot valve by filling with water; if ball fails to seal the seat, replace ball.

2. Thin material — contact manufacturer for proper thinning procedures.

3. Tighten all connections between pump and paint container. If damaged, replace. Switch to larger diameter siphon set.

1. Check upper seat and ball with water. If ball fails to seal, replace seat.

2. Replace packing set if worn.

1. Refill with new material. If too thick, remove siphon hose, immerse fluid section in material, and start pump to prime. Add thinner to material. Change to bigger siphon set. Open bleed valve to remove air and restart pump.

2. Remove foot valve. Clean ball and seat. 3. Straighten.

1. Check all connections between pump and gun. Tighten as necessary. If material is flowing from bleed hose, close bleed valve or replace, if necessary. Should none of the above be evident, replace lower packing.

2. Reseat balls by cleaning.

1. Replace. 2. Clean or replace filter. 3. Check electrical service. Correct as required. 4. Increase hose size to minimize pressure drop through

hose and/or reduce hose length.

1. Replace packing.

7. Troubleshooting

7.1 Airless Gun

7.2 Fluid Section

26 PowrTwin Plus

GBTroubleshooting

Problem A. Oil motor stalls at bottom (no

unusual heat problems)

B. Oil motor stalls at top (no unusual heat problems)

C. Low pressure (okay on down stroke, sluggish on up.stroke — high heat)

Note: Engine labors on upstroke, idles back at stall on the down stroke.

D. Low pressure (both strokes - high heat)

Note: Engine labors at stall on both strokes.

Cause 1. Fluid pump piston seat unthreaded

2. Valve sticking or oil motor trip rod shifter assembly separated

1. Valve sticking

2. Broken spring retainer (valve rod assembly) 3. Broken spring or valve rod 4. Air in hydraulic motor

5. Air in fluid pump

1. Blown piston seal

2. Cracked piston

1. Blown center o-rings on spool valve

2. Bad hydraulic pump

Solution 1. If connecting rod is okay, remove cylinder head plug

and pop valve down. Replace plug and start machine. If machine cycles up and stops at bottom again, then problem is piston seat on fluid pump. Check piston seat. Repair or replace as necessary. If piston seat is okay and problem does not change, check oil motor.

2. Remove valve and check for scratches and rough movement when sliding it up and down. Replace valve and spool in this condition. Check trip rod for possible separation.and spool in this condition. Check trip rod for possible separation.

1. Remove valve and check for scratches and rough movement when sliding it up and down. Replace valve and spool in this condition.

2. Replace valve rod assembly. 3. Replace valve rod assembly. 4. Reset valve. Purge Air, generally accomplished by low

pressure cycling of motor/pump assembly for 5–10 minutes. Check for causes of air introduction:

• Loose fittings in tank. • Loose fittings on hydraulic pump. • Loose hose connections. • Low oil in reservoir. 5. Stall at top can occur randomly when fluid pump picks

up air. Reset valve. Avoid air in the fluid pump.

1. Before dismantling oil motor, start machine. With pump cycling under pressure, touch the hydraulic cylinder and the head to see if cylinder or head gets hotter. This will help determine if piston seal is blown or piston nut is broken. If heat is on the head, check the o-rings on spool valve.

2. Dismantle oil motor and check piston seals cylinder bore and piston nut. Pay special attention to piston nut. It can be cracked and not show externally.

1. Before dismantling oil motor, start machine. With pump cycling under pressure, touch the head to see if the head becomes hotter. This will help determine if center o-ring is blown on spool valve. If hot, remove and replace o-ring.

2. Replace hydraulic pump.

7.3 Hydraulic Motors

PowrTwin Plus 27

GB Troubleshooting

Problem A. Tails

B. Hour glass

C. Distorted

D. Pattern expanding and contracting (surge)

E. Round pattern

Cause 1. Inadequate fluid delivery

1. Inadequate fluid delivery

1. Plugged or worn nozzle tip

1. Suction leak 2. Pulsating fluid delivery

1. Worn tip 2. Fluid too heavy for tip

Solution 1. Fluid not atomizing correctly: Increase fluid pressure. Change to smaller tip orifice size.

Reduce fluid viscosity. Reduce hose length. Clean gun and filter(s). Reduce number of guns using pump.

1. Same as above.

1. Clean or replace nozzle tip.

1. Inspect for suction hose leak. 2. Change to a smaller tip orifice size. Install pulsation

dampener in system or drain existing one. Reduce number of guns using pump. Remove restrictions in system; clean tip screen if filter is used.

1. Replace tip. 2. Increase pressure. Thin material. Change nozzle tip.

7.4 Spray Patterns

28 PowrTwin Plus

D

Warnung!Achtung: Verletzungsgefahr durch Injektion!

Airless-Geräte entwickeln extrem hohe Spritzdrücke.

Achte auf Sicherheit!

1

2

3

Niemals Finger, Hände oder andere Körperteile mit dem Spritzstrahl in Berührung bringen!Nie die Spritzpistole auf sich, Personen und Tiere richten.Nie die Spritzpistole ohne Spritzstrahl-Berührungsschutz benutzen.Behandeln Sie eine Spritzverletzung nicht als harmlose Schnittver-letzung. Bei einer Hautverletzung durch Beschichtungsstoff oder Lösemittel sofort einen Arzt aufsuchen zur schnellen, fachkundigen Behandlung. Informieren Sie den Arzt über den verwendeten Beschichtungsstoff oder das Lösemittel.

Vor jeder Inbetriebnahme sind gemäß Betriebsanleitung folgende Punkte zu beachten: 1. Fehlerhafte Geräte dürfen nicht benutzt werden. 2. Titan-Spritzpistole sichern mit Sicherungshebel am Abzugsbügel. 3. Erdung sicherstellen. 4. Zulässigen Betriebsdruck von Hochdruckschlauch und Spritzpistole

überprüfen. 5. Alle Verbindungsteile auf Dichtheit prüfen.

Anweisungen zur regelmäßigen Reinigung und Wartung des Gerätes sind streng einzuhalten.Vor allen Arbeiten am Gerät und bei jeder Arbeitspause folgende Regeln beachten: 1. Spritzpistole und Hochdruckschlauch druckentlasten. 2. Titan-Spritzpistole sichern mit Sicherungshebel am Abzugsbüge. 3. Gerät ausschalten.

Übersetzung der Originalbetriebsanleitung

PowrTwin Plus 29

D Inhalt

Inhalt

Seite 1. Sicherheitsvorschriften für das Airless-Spritzen .................301.1 Erklärung der verwendeten Symbole ............................................301.2 Elektrische Sicherheit ...........................................................................311.3 Benzinmotoren-Betriebssicherheit .................................................321.4 Betanken (Benzinmotor) .....................................................................32

2. Anwendungsübersicht .....................................................................332.1 Einsatzgebiete ........................................................................................332.2 Beschichtungsstoffe .............................................................................33

3. Gerätebeschreibung .........................................................................333.1 Airless-Verfahren ...................................................................................333.2 Funktion des Gerätes ...........................................................................333.3 Erklärungsbild PT-Geräte mit Benzinmotor ................................343.4 Erklärungsbild PT-Geräte mit Elektromotor ................................353.5 Technische Daten PT-Geräte .............................................................363.6 Empfehlungstabelle für Airless Spritzdüse .................................37

4. Bedienung ..............................................................................................384.1 Einrichtung ..............................................................................................384.2 Vorbereitung eines neuen Spritzgeräts ........................................394.3 Vorbereitung der Farbe.......................................................................404.4 Farbgebung .............................................................................................414.5 Vorgehensweise bei Druckentlastung ..........................................41

5. Reinigung ...............................................................................................425.1 Besondere Reinigungshinweise bei Verwendung entflammbarer Lösungsmittel .......